Process of fabricating circuit structure

ABSTRACT

A process for forming a circuit structure includes providing a first composite-layer structure at first. A second composite-layer structure is then provided. The first composite-layer structure, a second dielectric layer and the second composite-layer structure are pressed so that a second circuit pattern and an independent via pad are embedded in the second dielectric layer, and the second dielectric layer is connected to the first dielectric layer. A first carrier substrate and a second carrier substrate are removed to expose a first circuit pattern and the second circuit pattern. At least one first opening that passes through the second dielectric layer and exposes the independent via pad is formed, and the first opening is filled with a conductive material to form a second conductive via that connects the independent via pad and a second via pad.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of an application Ser. No. 11/739,515, filed on Apr. 24, 2007, now pending, which claims the priority benefit of Taiwan application serial no. 96102835, filed on Jan. 25, 2007. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a circuit structure, and more particularly to a circuit structure and process thereof.

2. Description of Related Art

The kinds of circuit boards normally used inside an electronic apparatus include the rigid circuit board and the flexible circuit board. The dielectric layer of a rigid circuit board is made from a strong and tough material for carrying and electrically connecting electronic components located on a single plane. The dielectric layer of a flexible circuit board is made from a flexible material for electrically connecting two electronic components located on different planes. Due to spatial limitation or other factors, the rigid circuit board and the flexible circuit board may be combined and applied together.

Conventionally, the techniques for fabricating a rigid circuit board (from now on, the circuit board) include the lamination process and the build-up process.

In the lamination process, circuit patterns are separately fabricated on dielectric layers. The circuit patterns, the dielectric layers on which the circuit patterns are disposed, and a dielectric layer for connection are aligned and pressed in a single operation to form the circuit board. Next, a conductive through via process is performed to fabricate conductive through vias for electrically connecting the circuit patterns located in different layer counts.

In the build-up process, circuit patterns and dielectric layers are alternately fabricated on a core in sequence. In addition, conductive blind via processes are also performed in the process of fabricating the circuit patterns and the dielectric layers so that conductive blind vias for connecting the circuit patterns in different layer counts are formed.

Regardless of whether the lamination process or the build-up process is used, the conductive via process fabricates a conductive via by forming an opening in a single operation and then filling the opening with conductive material. However, this method of performing a single operation to form each opening is disadvantageous to fabricating a conductive via with a high aspect ratio.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a circuit structure for a conductive via with a high aspect ratio.

The present invention also provides a circuit structure that uses two-stage process to fabricate a single conductive channel for electrically connecting two circuit patterns in different layer counts.

As embodied and broadly described herein, the present invention provides a circuit structure. The circuit structure includes a first dielectric layer, a first circuit pattern, at least one first conductive via and at least one independent via pad. The first circuit pattern is embedded in the first dielectric layer and has at least one first via pad. The first conductive via passes through the first dielectric layer and connects to the first via pad. The independent via pad is disposed on a surface of the first dielectric layer away from the first via pad and connects to one end of the first conductive via. The circuit structure further includes a second dielectric layer, at least one second conductive via and a second circuit pattern. The second dielectric layer is disposed over the surface of the first dielectric layer where the independent via pad is disposed. The second conductive via passes through the second dielectric layer and connects to the independent via pad. The second circuit pattern is embedded in the second dielectric layer and located at a surface of the second dielectric layer away from the independent via pad. The second circuit pattern has at least one second via pad connected to the second conductive via.

In an embodiment of the present invention, the outer diameter of the independent via pad may be greater than an outer diameter of the first via pad.

In an embodiment of the present invention, the outer diameter of the independent via pad may be greater than an outer diameter of the second via pad.

The present invention also provides a process for forming a circuit structure. First, a composite-layer structure including a first carrier substrate, a first circuit pattern, a first dielectric layer, at least one first conductive via and at least one independent via pad is provided. The first circuit pattern including at least one first via pad is disposed on the first carrier substrate. The first dielectric layer is disposed over the first carrier substrate and the first circuit pattern. Furthermore, the first circuit pattern is embedded in the first dielectric layer. The first conductive via passes through the first dielectric layer and connects with the first via pad. The independent via pad is located at one end of the first conductive via away from the first via pad. Furthermore, the first conductive via connects the independent via pad and the first via pad. In addition, a second composite-layer structure including a second carrier substrate and a second circuit pattern is also provided. The second circuit pattern is disposed on the second carrier substrate. Next, the first composite-layer structure, a second dielectric layer and the second composite-layer structure are pressed together such that the second circuit pattern and the independent via pad are embedded in the second dielectric layer and the second dielectric layer is connected to the first dielectric layer. Next, the first carrier substrate and the second carrier substrate are removed to expose the first circuit pattern and the second circuit pattern. After that, at least one first opening that passes through the second dielectric layer and exposes the independent via pad is formed. Next, conductive material is used to fill the first opening so as to form a second conductive via that connects the independent via pad and the second via pad. In an embodiment of the present invention, the outer diameter of the independent via pad may be greater than the outer diameter of the first via pad.

In an embodiment of the present invention, the second circuit pattern may have a ring-shape pad. When the conductive material is being used to fill the first opening, the conductive material filling an empty space surrounded by the ring-shape pad and the ring-shape pad form a second via pad. In addition, the outer diameter of the independent via pad may be greater than the outer diameter of the second via pad.

In an embodiment of the present invention, the process for providing the foregoing first composite-layer structure includes the following steps. First, a first circuit pattern is formed on the first carrier substrate. Next, a first dielectric layer is formed over the first carrier substrate and the first circuit pattern. After that, a conductive layer is formed upon the first dielectric layer. At least one second opening that passes through the conductive layer and the first dielectric layer and exposes the first via pad is formed. Subsequently, conductive material is used to fill the second opening so as to form a first conductive via. The conductive via connects the first via pad and the conductive layer. Finally, the conductive layer is patterned to form the independent via pad.

In an embodiment of the present invention, another process for providing the foregoing first composite-layer structure includes the following steps. First, a first circuit pattern is formed on the first carrier substrate. Next, a first dielectric layer is formed over the first carrier substrate and the first circuit pattern. After that, at least one second opening that passes through the first dielectric layer and exposes the first via pad is formed. A patterned mask is formed on the first dielectric layer. The patterned mask has a mask opening that exposes the second opening. Next, conductive material is used to fill the second opening so as to form a first conductive via that connects to the first via pad, and then conductive material is used to fill the mask opening so as to form an independent via pad. Finally, remove the patterned mask.

In an embodiment of the present invention, another process for providing the foregoing second composite-layer structure is forming the second circuit pattern on the second carrier substrate.

Accordingly, the present invention fabricates a single conductive channel for electrically connecting two circuit patterns in different layers through a two-stage process. Hence, the conductive vias of a circuit structure may have a higher aspect ratio, thereby increasing the circuit density of the circuit structure or fitness to the design of special circuit structures. In addition, the outer diameter of the independent via pad may be greater than the outer diameter of the via pad above or below the independent via pad so as to enhance the tolerance of alignment between two circuit patterns, one above and one below the independent via pad. As a result, the process yield of the circuit structure is increased and the heat dissipating capacity of the circuit structure is improved.

It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

FIGS. 1A to 1E illustrate a process for fabricating a circuit structure according to an embodiment of the present invention.

FIGS. 2A to 2E illustrate a process for fabricating the first composite-layer structure in FIG. 1A.

FIGS. 3A to 3F illustrate another process for fabricating the first composite-layer structure in FIG. 1A.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.

FIGS. 1A to 1E illustrate a process for fabricating a circuit structure according to an embodiment of the present invention. As shown in FIG. 1A, a first composite-layer structure 100 is provided. The first composite-layer structure 100 has a first carrier substrate 110 and a first circuit pattern 120. The first circuit pattern 120 including at least one first via pad 122 is disposed upon the first carrier substrate 110. The first composite-layer structure 100 further includes a first dielectric layer 130 covering the first carrier substrate 110 and the first circuit pattern 120. Furthermore, the first circuit pattern 120 is embedded in the first dielectric layer 130. The first composite-layer structure 100 also includes at least one first conductive via 140 that passes through the first dielectric layer 130 and connects to the first via pad 122.

The first composite-layer structure 100 also includes at least one independent via pad 150 located at one end of the first conductive via 140 away from the first via pad 122. Moreover, the first conductive via 140 connects the independent via pad 150 and the first via pad 122. It shall be noted that the independent via pad 150 refers to the via pad having no connection with any conductive wire in a layer where the via pad is disposed.

As shown in FIG. 1A, a second composite-layer structure 200 is also provided. The second composite-layer structure 200 has a second carrier substrate 210 and a second circuit pattern 220. The second circuit pattern 220 is disposed on the second carrier substrate 210. In the present embodiment, the second circuit pattern 220 may be fabricated upon the second carrier substrate 210 by performing an additive process, a semi-additive process or a subtractive process.

As shown in FIG. 1B, the first composite-layer structure 100, the second dielectric layer 300 and the second composite-layer structure 200 are pressed together so as to embed the second circuit pattern 220 and the independent via pad 150 in the second dielectric layer 300 and connect the second dielectric layer 300 to the first dielectric layer 130. In the present embodiment, the material of the second dielectric layer 300 may be a resin. Furthermore, heat may be simultaneously applied to the second dielectric layer 300 in the pressing process so that the independent via pad 150 is embedded in the second dielectric layer 300.

As shown in FIG. 1C, remove the first carrier substrate 110 and the second carrier substrate 210 to expose the first circuit pattern 120 and the second circuit pattern 220. Therefore, the first circuit pattern 120 is embedded in the first dielectric layer 130 and located at a surface of the first dielectric layer 130 away from the independent via pad 150, while the second circuit pattern 220 is embedded in the second dielectric layer 300 and located at a surface of the second dielectric layer 300 away from the independent via pad 150.

As shown in FIG. 1D, at least one first opening 232 that passes through the second dielectric layer 300 and exposes the independent via pad 150 is formed. In the present embodiment, the method of forming the first opening 232 is performing a laser-drilling operation, for example.

As shown in FIG. 1E, conductive material is used to fill the first opening 232 so as to form a second conductive via 240 that connects the independent via pad 150 and the second circuit pattern 220. Here, the second conductive via 240, the independent via pad 150 and the first conductive via 140 may be regarded as a conductive channel. In the present embodiment, the method of filling the first opening 232 with conductive material is performing an electroplating process, for example.

When an electroplating process is performed to fill the first opening 232 with conductive material, an electroplated layer (not shown) is formed on the second dielectric layer 300 and the second circuit pattern 220. This electroplated layer must be removed to prevent a short circuit of the second circuit pattern 220.

As shown in FIG. 1E, the independent via pad 150 in the present embodiment may be fabricated in such a way that the outer diameter of the independent via pad 150 is greater than that of the first via pad 122. This may increase the tolerance of alignment between the first circuit pattern 120 and the second circuit pattern 220 and improve the corresponding process yield.

In the present embodiment, the second circuit pattern 220 has a ring-shape pad 222 as shown in FIG. 1D. Therefore, after filling the first opening 232 with conductive material, the conductive material filling an empty space surrounded by the ring-shape pad 222 and the ring-shape pad 222 together form a second via pad 222′ as shown in FIG. 1E. In addition, the independent via pad 150 may be fabricated in such a way that the outer diameter of the independent via pad 150 is greater than that of the second via pad 222′. This may also increase the tolerance of alignment between the first circuit pattern 120 and the second circuit pattern 220 and improve the corresponding process yield.

FIGS. 2A to 2E illustrate a process for fabricating the first composite-layer structure in FIG. 1A. As shown in FIG. 2A, a first circuit pattern 120 is formed on a first carrier substrate 110. In the present embodiment, the first circuit pattern 120 may be fabricated on the first carrier substrate 110 by performing an additive process, a semi-additive process or a subtractive process.

As show in FIG. 2B, a first dielectric layer 130 is formed over the first carrier substrate 110 and the first circuit pattern 120 and then a conductive layer 150′ is formed on the first dielectric layer 130. In the present embodiment, the first dielectric layer 130 and the conductive layer 150′ may be a prepreg and a copper foil respectively. In addition, the first dielectric layer 130 and the conductive layer 150′ may be a composite layer such as a resin coated copper (RCC) composite layer.

As shown in FIG. 2C, a second opening 132 that passes through the conductive layer 150′ and the first dielectric layer 130 and exposes the first via pad 122 is formed. In the present embodiment, the method of forming the second opening 132 is performing a laser-drilling operation, for example.

As shown in FIG. 2D, conductive material is used to fill the second opening 132 so as to form a first conductive via 140 that connects the first via pad 122 and the conductive layer 150′. In the present embodiment, the method of filling the opening 132 with conductive material is performing an electroplating process, for example.

As shown in FIG. 2E, the conductive layer 150′ is patterned to form an independent via pad 150. In the present embodiment, the step for patterning the conductive layer 150′ includes performing an etching operation.

FIGS. 3A to 3F illustrate another process for fabricating the first composite-layer structure in FIG. 1A. As shown in FIG. 3A, a first circuit pattern 120 is formed on a first carrier substrate 110. In the present embodiment, the first circuit pattern 120 may be fabricated on the first carrier substrate 110 by performing an additive process, a semi-additive process or a subtractive process.

As show in FIG. 3B, a first dielectric layer 130 is formed over the first carrier substrate 110 and the first circuit pattern 120. In the present embodiment, the first dielectric layer 130 is formed, for example, by pressing a prepreg or coating a liquid phase dielectric material.

As shown in FIG. 3C, a second opening 132′ that passes through the first dielectric layer and exposes the first via pad 122 is formed. In the present embodiment, the method of forming the second opening 132′ is performing a laser-drilling operation, for example.

As shown in FIG. 3D, a patterned mask 400 is formed on the first dielectric layer 130. The patterned mask 400 has a mask opening 402 that exposes the second opening 132′. In the present embodiment, the patterned mask 400 may be a patterned photoresist layer.

As shown in FIG. 3E, conductive material is used to fill the second opening 132′ so as to form a first conductive via 140 that connects to the first via pad 122. In the present embodiment, the method of filling the second opening 132′ with conductive material is performing an electroplating process, for example.

Also, as shown in FIG. 3E, conductive material is used to fill the mask opening 402 so as to form an independent via pad 150. In the present embodiment, the method of filling the mask opening 402 with conductive material is performing an electroplating process, for example. In addition, the first conductive via 140 and the independent via pad 150 may be formed integrally in a single process.

As shown in FIG. 3F, the patterned mask 400 is removed to expose a surface of the first dielectric layer 130 away from the first via pad 122.

Accordingly, the present invention fabricates a single conductive channel for electrically connecting two circuit patterns in different layer counts through a two-stage process. Hence, the conductive vias of a circuit structure may have a higher aspect ratio, thereby increasing the circuit density of the circuit structure or fitness to the design of special circuit structures.

In addition, the outer diameter of the independent via pad may be greater than the outer diameter of the via pad above or below the independent via pad so as to enhance the tolerance of alignment between two circuit patterns, one above and one below the independent via pad. As a result, the process yield of the circuit structure is increased and the heat dissipating capacity of the circuit structure is improved.

It will be apparent to those skilled in the art that various modifications and variations may be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. 

1. A process of fabricating a circuit structure, comprising: providing a first composite-layer structure, having: a first carrier substrate; a first circuit pattern, disposed on the first carrier substrate and having at least one first via pad; a first dielectric layer, disposed over the first carrier substrate and the first circuit pattern, and the first circuit pattern is embedded in the first dielectric layer; at least one first conductive via, passing through the first dielectric layer and connected to the first via pad; and at least one independent via pad, located at one end of the first conductive via away from the first via pad, and the first conductive via connects the independent via pad and the first via pad; providing a second composite-layer structure, having: a second carrier substrate; and a second circuit pattern, disposed on the second carrier substrate; pressing the first composite-layer structure, a second dielectric layer and the second composite-layer structure so that the second circuit pattern and the independent via pad are embedded in the second dielectric layer and the second dielectric layer is connected to the first dielectric layer; removing the first carrier substrate and the second carrier substrate to expose the first circuit pattern and the second circuit pattern; forming at least one first opening that passes through the second dielectric layer and exposes the independent via pad; and filling the first opening with conductive material to form a second conductive via that connects the independent via pad and the second via pad.
 2. The process of fabricating the circuit structure as claimed in claim 1, wherein an outer diameter of the independent via pad is greater than an outer diameter of the first via pad.
 3. The process of fabricating the circuit structure as claimed in claim 1, wherein the second circuit pattern further comprises a ring-shape pad such that, when the first opening is being filled by conductive material, the conductive material filling an empty space surrounded by the ring-shape pad and the ring-shape pad together form a second via pad.
 4. The process of fabricating the circuit structure as claimed in claim 3, wherein an outer diameter of the independent via pad is greater than an outer diameter of the second via pad.
 5. The process of fabricating the circuit structure as claimed in claim 1, wherein the step for providing the first composite-layer structure comprises: forming the first circuit pattern on the first carrier substrate; forming the first dielectric layer over the first carrier substrate and the first circuit pattern; forming a conductive layer on the first dielectric layer; forming at least one second opening, wherein the second opening passes through the conductive layer and the first dielectric layer and exposes the first via pad; filling the second opening with conductive material to form the first conductive via that connects the first via pad and the conductive layer; and patterning the conductive layer to form the independent via pad.
 6. The process of fabricating the circuit structure as claimed in claim 1, wherein the step for providing the first composite-layer structure comprises: forming the first circuit pattern on the first carrier substrate; forming the first dielectric layer over the first carrier substrate and the first circuit pattern; forming at least one second opening, wherein the second opening passes through the first dielectric layer and exposes the first via pad; forming a patterned mask on the first dielectric layer, wherein the patterned mask has a mask opening that exposes the second opening; filling the second opening with conductive material to form the first conductive via that connects to the first via pad; filling the mask opening with conductive material to form the independent via pad; and removing the patterned mask.
 7. The process of fabricating the circuit structure as claimed in claim 1, wherein the step for providing the second composite-layer structure comprises: forming the second circuit pattern on the second carrier substrate.
 8. The process of fabricating the circuit structure as claimed in claim 1, wherein the step for providing the first composite-layer structure comprises: forming the first circuit pattern on the first carrier substrate; forming the first dielectric layer over the first carrier substrate and the first circuit pattern; forming at least one second opening, wherein the second opening passes through the first dielectric layer and exposes the first via pad; and filling the second opening with conductive material to form the first conductive via that connects the first via pad and the conductive layer forming the independent via pad on the first conductive via. 